2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 1
Innovative High Temperature Heat Pump
Ing. Bruno Vanslambrouck
HOWEST/Ghent University,
Research Group on Thermal
Energy in Industry (TEI)
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 2
Presentation overview
1. High Temperature Industrial Heat Pumps (HT IHP)
2. How to power a HT IHP ?
3. Case study from food industry
4. HT IHP R&D projects
5. HOWEST – ESSET/E2S project
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 3
Presentation overview
1. High Temperature Industrial Heat Pumps (HT IHP)
2. How to power a HT IHP ?
3. Case study from food industry
4. HT IHP R&D projects
5. HOWEST – ESSET/E2S project
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 4
Example:
Waste heat temperature: 30°C
Desired process heat temp: 80°C
COP = 353 / (353 – 303) = 7 (Theoretical optimum according to Carnot)
In fact: about 50-60% of Carnot eff., in this case 3,5 à 4,2
Profit of an electrical driven heat pump:
- Primary energy savings when COP > 1/eff E-production, being about 2,5
- Gain on energy costs if COP > E-price/Heat cost (2,5 à 4 within industry)
IHP: bigger as for residential use
HT IHP: heat flow temp
output from ca 65-70°C !
Limit (current market supply):
ca 90°C !!
High Temp Industrial HP
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 5
High Temp Industrial HP
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 6
How to realize HPs for higher temperature regimes ?
Some (low temperature) ORC’s are in fact reversed cooling devices: - evaporator and condenser are switched
- compressor becomes expander, motor becomes generator
- expansion valve replaced by a pump
- system pressure increased to evaporate/condense on higher t° level
Example: ORC (right) to
produce electricity from
(geothermal) hot water of
75-85°C, if ambient t° <
5°C (Alaska), derived from
a Carrier chiller (left)
High Temp Industrial HP
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 7
To further increase evaporator/condenser temperatures when max
pressure level is reached, working fluid can be changed.
Example: previous ORC can convert waste heat on 140°C (or more) into electricity
on “normal” ambient temperatures after replacing R134a by R245fa.
This is the well known Pure Cycle 280
(250 kWe) ORC of Pratt&Whitney
High Temp Industrial HP
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 8
High temperature heat pump:
- Keep configuration as a cooling device
- Increase pressure (to max allowable )
and switch working fluid
- Reverse temperature differences
over evaporator and condensor
Example:
The Pure Cycle 280 could be
“reversed” to produce 110-115°C
process heat from 40-50°C waste heat
High Temp Industrial HP
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 9
Presentation overview
1. High Temperature Industrial Heat Pumps (HT IHP)
2. How to power a HT IHP ?
3. Case study from food industry
4. HT IHP R&D projects
5. HOWEST – ESSET/E2S project
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 10
Important: which COP could be reached ?
Realistic goal on HT IHP: COP = 2,5 or higher, depending on t°-diff
between low and high t° stream (the smaller the better).
On current industrial energy prices (ca EUR 30/MWh gas and EUR
90/MWh E), energy costs savings by using an E-powered HT IHP
only to realize if the COP exceeds 3 !
Solution when COP < 3 à 4 (often on HT IHP):
Power the HT IHP directly with a thermal machine (internal
combustion engine or gas turbine).
Waste heat from this machine is to integrate into the entity (jacket
cooling water on the input or output side, surheating output using
exhaust gas heat to realize smaller delta t all over the heat pump)
How to power a HT IHP ?
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 11
Heat
Exchanger
Combustion
Engine
Waste Heat
Boiler Condenser
Evaporator
Exhaust Gases, 480°C Expansion
Device
Compressor
4 MW
3 MW
500 kW 650 kW
1 MW η=42% Fuel in: 2,38 MW
95 l/s, 60°C
90°C
70°C 71,3°C
75°C
20°C 20°C
COP = 4
Heat Source (Water) 48 l/s, 40°C
25°C
85°C
Heat Sink
72,9°C
Cooled Exhaust Gases, 90°C
η =P + Q
Fuel=
1 + 1,15
2,38= 90,3%
η =Q
Fuel =
4 + 1,15
2,38= 216%
CHP:
CHP + HP:
Example 1:
How to power a HT IHP ?
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 12
Combustion
Engine
Waste Heat
Boiler Condenser
Evaporator
Exhaust Gases, 480°C Expansion
Device
Compressor
3 MW
2 MW:
1,5 recuperation +
0,5 Jacket cooling
600 kW
1 MW, η=42% Fuel in: 2,38 MW
100°C Saturated Steam 5 bar, 159°C
170°C
80°C 80°C
COP = 3
Heat Source (Vapors), 95°C
85°C
Cooled Exhaust
Gases, 120°C
85°C 90°C
Example 2:
How to power a HT IHP ?
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 13
Source: MAN Dezentrale
Energiesysteme, 1995
How to power a HT IHP ?
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 14
Presentation overview
1. High Temperature Industrial Heat Pumps (HT IHP)
2. How to power a HT IHP ?
3. Case study from food industry
4. HT IHP R&D projects
5. HOWEST – ESSET/E2S project
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 15
Case from food industry
Boundary conditions:
- Waste heat available as vapors from a frying process (about 3 MW recoverable,
mainly latent heat @ 95°C)
- Process heat needed to reheat frying oil
from ca 150 tot 180°C (about 4,8 MW)
First approach(*): - 1-stage compressor
- Evaporator temp about 80°C
- Condensor temp about 180°C
(further heating by use of engine exhaust)
- Max system pressure about 25 bar
- Max pressure ratio about 10
* Mechanical Vapor Recompression rejected because of oil content vapor
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 16
Working fluid selection:
Focus on commonly used ORC fluids: cooling fluids, silicone-oils, organic fluids
such as pentane, toluene,…
Selection criteria are:
• Tcrit > 180°C
• psat 180°C < 25 bar
• psat 80°C > 1 bar (if possible, to avoid vacuum)
• Boiling point < 90°C
• Pratio 80-180° < 10 (common screw compressor)
Case from food industry
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 17
Fluidname Formula Tcr [°C] pcr [bar] 180 80
pentane C5H12 196,6 33,68 26,33 3,69 7
R113 R113 214,2 34,10 20,46 2,64 8
toluene C7H8 318,7 41,06 5,20 0,39 13
Hexamethyldisiloxane HMDS 245,5 19,51 6,58 0,53 12
Octamethyltrisiloxane OMTS 291,0 14,15 1,96 0,09 21
R11 (*) R11 198,0 44,03 33,84 5,20 7
R365mfc R365mfc 186,9 32,66 29,01 3,52 8
Cyclopentane C5H10 238,6 45,10 19,58 2,52 8
water H2O 374,1 220,90 10,02 0,47 21
cyclohexane C6H12 280,49 40,75 9,75 0,99 10
hexane C6H14 234,15 30,1236 13,17 1,42 9
Psat [bar] on Tsat [°C]Pressure
ratio
(180/80)
Some results (candidate fluids):
Case from food industry
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 18
HP simulation with Cycle Tempo (simple configuration)
Medium : cyclopentane
COP = 2648 kW / 1053 kW = 2,5 ( 55% of Carnot-limit)
Case from food industry
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 19
HP – simple configuration
Case from food industry
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 20
HP – cycle with recuperator
COP = 3017 kW / 1053 kW
= 2,9
(64% of Carnot-limit)
Case from food industry
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 21
HP – cycle with recuperator
Case from food industry
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 22
HP – cycle with recuperator
Case from food industry
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 23
Calculation Pmech and Pth
Pmech 1452 kW Fryer vapor heat recuperation
Pth out,HP (= Pmech x COP) 4211 kWth Pfryer vapour 2759 kWth
Pth,recup (ex gases ) 589 kWth
Pth out,HP + Pth,recup 4800 kWth (thermal energy to fryer)
Gas consumption
PNG 3377 kWth (Pmech/eff. gas engine)
Gas savings 36,7% (Assume boiler eff. = 90%)
HP–cycle with recuperator:
energy savings by using a gas engine for driving an (expensive)
process gas compressor with discharge t° over 230°C
Case from food industry
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 24
1. High Temperature Industrial Heat Pumps (HT IHP)
2. How to power a HT IHP ?
3. Case study from food industry
4. HT IHP R&D projects
5. HOWEST – ESSET/E2S project
Presentation overview
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 25
HT IHP R&D projects
EDF R&D France
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 26
HT IHP R&D projects
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 27
HT IHP R&D projects
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 28
HT IHP R&D projects
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 29
HT IHP R&D projects
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 30
HT IHP R&D projects
Coordinator: EDF-R&D
Partners:
JOHNSON CONTROLS, FRANCE EVAPORATION,
AGROPARISTECH, CETHIL,IPB-ENSEIRB-
MATMECA
Duration of project:
4 years (December 2009 - December 2013)
Total budget of the project: 3.2 million €
Goal: to develop an industrial water based heat
pump, to recycle high-temperature waste heat
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 31
HT IHP R&D projects
Why water ?
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 32
Results:
- HP with screw compressor: 92°/137°C evaporator/condensor t°
realized but mechanical efficiency evaluated as too low
- with magnetic driven centrifugal compressor: mechanical/thermal
validation in progress.
Expected results:
COP = 5,5 on 85°/125°C
regime
HT IHP R&D projects
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 33
HT IHP R&D projects
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 34
HT IHP R&D projects
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 35
HT IHP R&D projects
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 36
Thermoacoustic heat
transformer
Waste heat temperature: 140°C
Process heat temperature: 190°C
HT IHP R&D projects
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 37
1. High Temperature Industrial Heat Pumps (HT IHP)
2. How to power a HT IHP ?
3. Case study from food industry
4. HT IHP R&D projects
5. HOWEST – ESSET/E2S project
Presentation overview
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 38
Test facility @ HOWEST
Originally designed for ORC test and demonstration but also adapted
for:
- Heat pump test and demonstration
- Heat exchanger tests
- Heat storage tests (e.g. PCM)
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 39
High temperature heat pump – Lab setup (ESSET)
HOWEST-ESSET/E2S
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 40
Industrial project: ESSET/E2S
Development of a HT IHP, derived from a
Modified towards a completely open heat pump
Heat source:
Thermal oil
Heat sink:
water/glycol
120°C
80°C
HOWEST-ESSET/E2S
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 41
Superheating after compressor to avoid by fluid injection:
HOWEST-ESSET/E2S
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 42
HOWEST-ESSET/E2S
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 43
Pressure ratio
HOWEST-ESSET/E2S
2nd User Group Meeting, MIROM Roeselare PFI Workshop Heat Pumps in CHP Bruno Vanslambrouck 03/09/2013 44
Graaf Karel de Goedelaan 5, B-8500 Kortijk
Mail: [email protected]
Tel: +32 56 241211 of +32 56 241227 (dir)
www.ugent.be ww.wasteheat.eu
www.cornet-w2pheat.eu
Contact
Thanks to all of you for your attention
Time for questions…discussion ?
Ing. Bruno Vanslambrouck
HOWEST/Ghent University,
Research Group on Thermal Energy in Industry (TEI)